INTRODUCTION TO MECHANICAL ENGINEERING

MODULE-3
Introduction to IC Engines: Components and Working Principles, 4-Strokes Petrol and Diesel Engines,
Application of IC Engines.

Insight into Future Mobility; Electric and Hybrid Vehicles, Components of Electric and Hybrid
Vehicles. Advantages and disadvantages of EVs and Hybrid vehicles.

Introduction to IC Engines
An Engine is a machine designed to convert one form of energy into mechanical energy.

An engine or Heat engine can be defined as a device or machine that converts chemical energy of fuel into
mechanical energy to perform useful mechanical work.

Heat engines are of two types

1. Internal Combustion Engine

2. External Combustion Engine

Internal Combustion Engine:

If the combustion of the fuel takes place inside the engine cylinder then it is called as internal combustion
engine (IC engine).
E.g. petrol engine, diesel engine.

External Combustion Engine:

If the combustion of the fuel takes place outside the engine cylinder then it is called as external combustion
engine (EC engine).
E.g. steam engine

Components of IC Engine
a) Cylinder: It is consider as heart of engine because combustion takes place inside the cylinder. It also
guides the piston to reciprocate inside the cylinder.
b) Cylinder Head: It is a removable cover placed on the top of the cylinder; it incorporates inlet &
exhaust valves and spark plug or fuel injector.
c) Piston: It is a cylindrical shaped component placed inside the cylinder. Piston moves to and from
(reciprocator) inside the cylinder and transmit the power from cylinder to crankshaft.
d) Valves: There are two types of valves: (i) inlet valve and (ii) exhaust valve
(i) Inlet valve: Through the inlet valve air or air and fuel mixture enters into the cylinder.
(ii) Exhaust valve: Through the exhaust valve the burnt gases are moved out of the cylinder.
e) Piston Rings: These are placed at the edges of the piston. It provides tight seal between the piston
and cylinder in order to prevent the leakages.

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 f) Connecting Rod: It connects between the piston and crankshaft. It converts the reciprocator motion
of the piston to rotary motion of the crankshaft.
g) Crankshaft: It transmits the power generated in the engine to the flywheel.
h) Flywheel: It is the element used to maintain uniform speed of the crankshaft and also stores the
energy.
i) Cams: It is an element designed to control the opening and closing of inlet and exhaust valves.

4 Stroke Petrol Engine

A four-stroke petrol engine works on Otto cycle. Hence, it is also called Otto cycle engine. The charge used
in a 4-s petrol engine is a mixture of air and petrol, and is supplied by the carburetor in suitable proportions.
The charge is ignited by the spark generated by a spark plug, and for this reason, petrol engines are also
called Spark Ignition (SI) engines.

The four different strokes performed are:

a) Suction stroke
b) Compression stroke
c) Power stroke or Expansion stroke or Working stroke
d) Exhaust stroke

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Working

a) Suction stroke

At the beginning of the suction stroke, the piston is at the top dead center (TDC), and is about to move
towards the bottom dead center (BDC). The inlet valve is opened and the exhaust value is closed. The
downward movement of the piston produces suction (partial vacuum) in the cylinder, due to which air and
petrol mixture is drawn into the cylinder through the inlet valve.

When the piston reaches the BDC, the suction stroke ends and the inlet valve is closed. The suction of air
takes place at atmospheric pressure, and is represented by the line ‘ab’ on p-v diagram.

b) Compression stroke

During the compression stroke, the piston moves from BDC to TDC. Both the inlet and exhaust valves
remain closed. As the piston moves upwards, the air-petrol mixture in the cylinder gets compressed
(squeezed), due to which the pressure and temperature of the mixture increases and is shown by the curve
‘bc’ on p-v diagram.

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When the piston is about to reach the TDC, the spark plug initiates a spark that ignites the air-petrol
mixture. Combustion of fuel takes place at constant volume as shown by the line ‘cd’ on p-v diagram.

c) Power stroke (Expansion stroke or Working stroke)

During this stroke, both the valves will remain closed. As the combustion of fuel takes place, the burnt gases
exert a large force on the piston causing it to move from the TDC to BDC. The force (or power) is
transmitted to the crankshaft through the connecting rod. As a result, the crankshaft rotates at high speeds.
The crankshaft then transmits to turn the wheels of the vehicle and cause it to move. The expansion of gases
is is shown by the curve ‘de’ on p-v diagram.

d) Exhaust stroke

During this stroke, the exhaust valve opens, while the inlet valve remains closed. A part of the burnt gases
due to their own expansion escapes out of the cylinder through the exhaust valve. This drop in pressure at
constant volume inside the cylinder is represented by the line ‘eb’ on p-v diagram.

The exhaust stroke begins when the piston starts moving from the BDC to TDC. As the piston moves
upwards, it forces the remaining burnt gases to the atmosphere through the exhaust valve. The exhaust
taking place at atmospheric pressure is shown by the line ‘ba’ on p-v diagram.

4 Stroke Diesel Engine

A four-stroke diesel engine works on diesel cycle. Hence, it is also called Diesel cycle engine.

The four different strokes performed are:

a) Suction stroke
b) Compression stroke
c) Power stroke or Expansion stroke or Working stroke
d) Exhaust stroke

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a) Suction stroke

At the beginning of the suction stroke, the piston is at the top dead center (TDC), and is about to move
towards the bottom dead center (BDC). The inlet valve is opened and the exhaust value is closed. The
downward movement of the piston produces suction (partial vacuum) in the cylinder, due to which air from
the atmosphere is drawn into the cylinder through the inlet valve. When the piston reaches the BDC, the
suction stroke ends and the inlet valve is closed. The suction of air takes place at atmospheric pressure, and
is represented by the line ‘ab’ on p-v diagram.

b) Compression stroke

During the compression stroke, the piston moves from BDC to TDC. Both the inlet and exhaust valves
remain closed. As the piston moves upwards, the air in the cylinder gets compressed (squeezed), due to
which the pressure and temperature of the air increases is shown by the curve ‘bc’ on p-v diagram.

When the piston is about to reach the TDC, diesel oil is injected in into the hot compressed air by a fuel
injector. Combustion of fuel takes place at constant pressure as shown by the line ‘cd’ on p-v diagram. Since
combustion of fuel takes place at constant pressure, 4-s diesel engines are also called as constant pressure
cycle engines.

c) Power stroke (Expansion stroke or Working stroke)

During this stroke, both the valves will remain closed. As the combustion of fuel takes place, the burnt gases
expand and exert a large force on the piston causing it to move rapidly from the TDC to BDC. The force (or
power) is transmitted to the crankshaft through the connecting rod. As a result, the crankshaft rotates at high
speeds. The crankshaft then transmits the power to turn the wheels of the vehicle. The expansion of gases is
shown by the curve ‘de’ on p-v diagram.

d) Exhaust stroke

During this stroke, the exhaust valve opens, while the inlet valve remains closed. A part of the burnt gases
due to their own expansion escapes out of the cylinder through the exhaust valve. This drop in pressure at
constant volume inside the cylinder is represented by the line ‘eb’ on p-v diagram.The exhaust stroke begins
when the piston starts moving from the BDC to TDC. As the piston moves upwards, it forces the remaining
burnt gases to the atmosphere through the exhaust valve. The exhaust taking place at atmospherisc pressure
is shown by the line ‘ba’ on p-v diagram.

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Difference Between 4-S Petrol and 4-S Diesel engine

4-S Petrol Engine 4-S Diesel Engine

During suction stroke, air and petrol mixture enters During suction stroke only atmospheric air enters
into the cylinder. into the cylinder
It is also known as constant volume process. It is also known as constant pressure process.
It is a spark ignition engine. It is a compression ignition engine.
It works on otto cycle. It works on diesel cycle.
Power developed is less. Power developed is more.
Mileage is less. Mileage is more.
Maintenance cost is low. Maintenance cost is high.

Applications of IC Engines

IC engines for Automobiles

An automobile is a self-propelled vehicle that travels on land. It consist an internal combustion engine
which provides the power and the vehicle runs on the wheels. The primary function of an automobile is to
carries people and goods from one place to another. All bikes, cars, truck etc. include in it.

IC engines for Power Generation

A generating station in which diesel engine is used as the prime mover for the generation of electrical
energy is known as diesel power station.

Diesel engine power stations are used when demand of power is less, sufficient quantity of coal and water is
not available and the transportation facilities are inadequate.

This plants are also standby sets for continuity of supply to important points such as hospitals, radio
stations, cinema houses and telephone exchanges.

IC engines in Agriculture
The source of power for agricultural production has shifted from humans to animals, to internal combustion
engines (gasoline and diesel).

Agricultural mechanization uses basically Diesel internal combustion engines, as most agricultural
operations are carried out in motion, for tractors, harvesters, and self-propelled sprinklers, etc...

Engines allow faster production, more food to be grown and harvested. Farm equipment and machinery are
the heart of the agricultural industry. Tractors and planters are all powered with engines to plant and harvest
crops.
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IC engines in Marine
Marine propulsion is the mechanism or system used to generate thrust to move a ship or boat across water.
While paddles and sails are still used on some smaller boats, most modern ships are propelled by
mechanical systems consisting of an electric motor or engine turning a propeller,

Marine diesel engines are very similar to the self-ignition engines in heavy-duty vehicles, but they are
generally larger, more complex, and operate with higher efficiency. About 75% of all marine diesel engines
are four-stroke engines.

IC engines in Aircraft Propulsion

Today, most general aviation or private airplanes are still powered by propellers and internal combustion
engines, much like automobile engine.

ELECTRIC VEHICLES
Electric vehicles (EV) are vehicles drives with electric motors and draw power from battery. It is more
durable and mechanically simpler than petrol vehicle. It gives more fuel efficiency than petrol engine
because it does not produce emission like Internal combustion engine.

Components:

1. Battery pack: It powers the electric motor of an electric vehicle. It stores energy in the form of DC
current. The range will be higher with increasing KW of the battery. Auxiliary batteries are also used
to charge while running.
2. DC-DC Converter: The battery pack delivers a constant voltage. But different components of the
vehicle have different requirements. The DC-DC converter is used to distribute the output power that
is coming from the battery to a required level.
3. Controller: It performs the regulation of electrical energy from the batteries to the electric motors.
The accelerator by the driver determines the speed of the car and frequency of variation of voltage
that is input to the motor.
4. Electric Motor: It is the main component of the electric vehicle. The motor converts the electrical
energy into mechanical energy by rotating the wheels.

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 5. Power inverter: It converts DC power from the batteries to AC power. It also converts the AC
current generated during regenerative braking system into DC current.
6. Charging Port: The charge port connects the electric vehicle to an external supply. It charges the
battery pack.

Working: Battery is the energy source which is charged by taking electric current from the grid.
Electricity is transferred from a battery to a controller. The controller then sends the electricity to the electric
motors when needed. The accelerator is connected to a variable switch which tells the controller how
much power to send to the electric motors. Power output can vary from zero to full as needed. Motor
transmit the power to the wheels of the vehicle by the use of transmission system.

Advantages
 No fuel required
 Extremely quiet
 Zero emissions when driving
 Gearbox free
 Easy to drive
 Lower maintenance cost
 Tax efficient

Disadvantages
 Expensive to buy
 Limited range
 Lack of charging stations
 Longer time to recharge
 Battery life concerns

HYBRID VEHICLE

The term hybrid vehicle refers to a vehicle with at least two sources of power. A hybrid-electric
vehicle indicates that one source of power is provided by an electric motor. The other source of
motive power provided by an internal combustion engine designed to run on either petrol or diesel
fuel.

Components:

1. Battery pack: It powers the electric motor of an electric vehicle. It stores energy in the form of DC
current. The range will be higher with increasing KW of the battery. Auxiliary batteries are also used
to charge while running.

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 2. DC-DC Converter: The battery pack delivers a constant voltage. But different components of the
vehicle have different requirements. The DC-DC converter is used to distribute the output power that
is coming from the battery to a required level.
3. Controller: It performs the regulation of electrical energy from the batteries to the electric motors.
The accelerator by the driver determines the speed of the car and frequency of variation of voltage
that is input to the motor.
4. Electric Motor: It is the main component of the electric vehicle. The motor converts the electrical
energy into mechanical energy by rotating the wheels.
5. Fuel tank: It stores the fuel required for the internal combustion engine.
6. IC engine: Power is developed by combustion of fuel in the engine. The power stored in the
flywheel is transmitted to the wheels of the vehicle.
7. Regenerative braking system: Generates electricity from the rotating wheels while braking, it
transfers energy to the battery pack.

Working:

 Has a fuel tank that supplies petrol/diesel to the engine like a regular car
 It also has a set of batteries that run an electric motor
 Both the engine and electric motor can turn the transmission at the same time
 Transmission system transfers the power to the wheels.
 A hybrid electrical vehicle cannot be plugged into charge the battery. Instead, the battery is charged
through regenerative braking system and by the IC engine.

Advantages

 Less Dependence on Fossil Fuels

 Regenerative Braking System
 Reduces noise pollution
 Fuel economy
 Lower emissions

Disadvantages

 More expensive than battery operated electric vehicle

 Space required for IC engine, motor and battery is more
 Power produced is less than petrol engine.
 Higher maintenance cost
 Expensive battery replacement charges

Department of Mechanical Engineering, CBIT, KOLAR